Engine Front Cover

Special Tool(s)

	3 Jaw Puller 303-D121 or equivalent
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A2 plate only)
	Installer, Front Crank Seal and Damper 303-1531
	Remover, Oil Seal 303-409 (T92C-6700-CH)
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Engine Front Cover (View 1 of 4)

Engine Front Cover (View 2 of 4)

Engine Front Cover (View 3 of 4)

Engine Front Cover (View 4 of 4)

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Release the fuel system pressure. For additional information, refer to Section 310-00 .

3. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

4. Drain the engine cooling system. For additional information, refer to Section 303-03A .

5. Remove the RH and LH valve covers. For additional information, refer to Valve Cover — RH and Valve Cover — LH in this section.

6. Remove the engine coolant degas bottle. For additional information, refer to Section 303-03A .

7. Remove the cooling fan motor and shroud. For additional information, refer to Section 303-03A .

8. Loosen the 4 coolant pump pulley bolts.

9. Remove the accessory drive and A/C compressor belts. For additional information, refer to Section 303-05 .

10. Disconnect the lower radiator hose from the thermostat housing assembly.

11. Remove the 2 thermostat housing bolts.

12. Release the clamp and position the upper radiator hose T-connector/thermostat housing assembly aside.
    • Remove and discard the thermostat housing O-ring seal.

13. Disconnect the heater hose. For additional information, refer to Section 412-00 .

14. Remove the 4 bolts and the coolant pump pulley.

15. Remove the 4 bolts and the coolant pump.
    • Remove and discard the O-ring seal.

16. Disconnect the throttle body and Evaporative Emission (EVAP) purge valve electrical connectors.

17. Detach the 3 wiring harness retainers from the engine front cover and stud bolt.

18. Remove the bolt and the accessory drive belt tensioner.

19. Remove the nut, the bolt and position the generator aside.

20. Remove the crankshaft pulley bolt and washer.

21. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
    • Discard the crankshaft pulley bolt.

22. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

23. Remove the 3 bolts and lower the underbody shield.

24. Remove the 2 wiring harness retainer nuts from the front oil pan stud bolts.

25. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.

26. Remove the 13 engine front cover bolts and the 2 stud bolts.

27. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    Remove the engine front cover from the front cover to cylinder block dowel.
    • Remove and discard the engine front cover gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.

28. Drain the engine oil.
    • Install the drain plug and tighten to 26 Nm (19 lb-ft).

Installation

1. NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

   NOTE: LH shown, RH similar.

   Fully depress the VCT variable force solenoid pins.

2. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

   Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.

3. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.

   Using new gaskets, position the engine front cover onto the dowels.
   • Install the 13 engine front cover bolts, 2 stud bolts and the 4 oil pan-to-engine front cover bolts finger-tight.

4. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

   Tighten the bolts in the sequence shown in 2 stages.
   • Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).
   • Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.

5. Position the wiring harness and install the 2 wiring harness retainer nuts to the front oil pan stud bolts.

6. Position the underbody shield and install the 3 bolts.
   • Tighten to 10 Nm (89 lb-in).

7. NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.

   Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.

8. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

   Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.

9. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

10. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.

11. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
    • Stage 1: Tighten to 140 Nm (103 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 100 Nm (74 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

12. Install the generator, the bolt and the nut.
    • Tighten to 48 Nm (35 lb-ft).

13. Install the accessory drive belt tensioner and bolt.
    • Tighten to 48 Nm (35 lb-ft).

14. Attach the 3 wiring harness retainers to the engine front cover and stud bolt.

15. Connect the throttle body and Evaporative Emission (EVAP) purge valve electrical connectors.

16. NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.

    Using a new O-ring seal, install the coolant pump and the 4 bolts.
    • Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.

17. Install the coolant pump pulley and the 4 bolts.

18. Connect the heater hose. For additional information, refer to Section 412-00 .

19. NOTE: Lubricate the new thermostat housing O-ring seal with clean engine coolant.

    Using a new thermostat housing O-ring seal, install the upper radiator hose T-connector/thermostat housing assembly.

20. Install the 2 thermostat housing bolts.
    • Tighten to 10 Nm (89 lb-in).

21. Connect the lower radiator hose to the thermostat housing assembly.

22. Install the accessory drive and A/C compressor belts. For additional information, refer to Section 303-05 .

23. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).

24. Install the cooling fan motor and shroud. For additional information, refer to Section 303-03A .

25. Install the engine coolant degas bottle. For additional information, refer to Section 303-03A .

26. Install the RH and LH valve covers. For additional information, refer to Valve Cover — RH and Valve Cover — LH in this section.

27. Fill the crankcase with clean engine oil.

28. Connect the battery ground cable. For additional information, refer Section 414-01 .

29. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03A .

30. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.